Power supply controller with minimum-sum multi-cycle modulation

ABSTRACT

An example power supply controller includes a signal separator circuit that generates a feedback signal. An error signal generator generates an error signal in response to the feedback signal. A control circuit generates a drive signal in response to the error signal. The drive signal controls switching of a switch. A multi-cycle modulation circuit is included in the control circuit and generates a skip signal in response to a start skip signal, a stop skip signal and a skip mask signal. The skip mask signal is generated in response to the skip signal. The start skip and stop skip signals cause the drive signal to start skipping or stop skipping, respectively, on-time intervals of cycles. The skip mask signal disables the start skip signal from causing the drive signal to start skipping the on-time intervals of cycles.

BACKGROUND INFORMATION

1. Field of the Disclosure

This invention is related to power supplies. In particular, theinvention is related to controllers for switching power supplies.

2. Background

In a typical application, an ac-dc power supply receives an input thatis between 100 and 240 volts rms at a relatively low frequency that isnominally either 50 Hz or 60 Hz from an ordinary ac electrical outlet.The ac input voltage is usually rectified within the power supply tobecome a source of unregulated dc voltage for use by a dc-dc switchingpower converter. Switches in the power converter are typically switchedon and off at a relatively high frequency (tens or hundreds ofkilohertz) by a control circuit to provide a regulated output that maybe suitable for operating an electronic device, or for charging abattery that provides power to an electronic device.

The design of a switching power supply is usually a compromise amongconflicting requirements of efficiency, size, weight, and cost. Theoptimal solution that delivers the rated output power usually sets theswitching frequency much higher than 20 kHz, outside the range of humanhearing.

Regulatory requirements limit the amount of energy power supplies canconsume when they operate at low loads, such as standby loads and at noload. When a switching power supply delivers much less than its ratedpower, the energy lost within the power supply is dominated by lossesfrom the action of switching. Therefore, it is beneficial for the powersupply to operate at lower switching frequencies when the output poweris low to reduce the dominant losses.

The optimal switching frequency at low power often falls within the bandof audio frequencies below 20 kHz. Switching within the band of audiofrequencies can produce undesirable audio noise that results frommechanical excitation of electrical and magnetic components in the powersupply. It is difficult to adjust the frequency of an oscillator in acontinuous way to avoid the undesirable audio frequencies while meetingrequirements for the power supply to be stable and to respond adequatelyto changes in load.

To overcome this difficulty, controllers for power supplies typicallyset an oscillator at a fixed frequency, and they regulate the output byallowing and preventing switching during the switching periods definedby the oscillator. The switching periods of the oscillator are sometimesreferred to as switching cycles. The resulting groups of consecutiveswitching and non-switching periods produce an effective switchingfrequency that may be substantially less than the frequency of theoscillator. The effective switching frequency may be thought of as anaverage switching frequency that is substantially the fixed oscillatorfrequency multiplied by the ratio of the number of times switchingoccurs in a large number of consecutive switching periods divided by thelarge number of consecutive switching periods.

The switching periods where switching occurs are sometimes calledenabled switching periods and the periods where switching is preventedare sometimes called disabled switching periods or skipped switchingperiods. It is important to distribute the enabled periods and theskipped periods in a way that avoids the generation of audio noise whileallowing the power supply to switch often enough for it to respondadequately to changes in load. The requirement for galvanic isolationcan place restrictions on the grouping of enabled periods and skippedperiods.

Safety agencies generally require galvanic isolation between the inputand the output of an ac to dc power supply. Galvanic isolation preventsdc current between the input and the output of the power supply. Inother words, a high dc voltage applied between an input terminal and anoutput terminal of the power supply will produce no dc current betweenthe input terminal and the output terminal of the power supply. Therequirement for galvanic isolation is a complication that contributes tothe cost of the power supply and to the difficulty of avoiding switchingat undesirable audio frequencies.

A power supply with galvanic isolation must maintain an isolationbarrier that electrically separates the input from the output such thatcircuits on the input side of the isolation barrier are galvanicallyisolated from the circuits on the output side of the isolation barrier.Energy must be transferred across the isolation barrier to provide powerto the output, and information in the form of signals must betransferred across the isolation barrier to regulate the output.Galvanic isolation is typically achieved with electromagnetic andelectro-optical devices. Electromagnetic devices such as transformersand coupled inductors are generally used to transfer energy betweeninput and output to provide output power, whereas electro-opticaldevices are generally used to transfer signals between output and inputto control the transfer of energy between input and output.

Efforts to reduce the cost of the power supply have focused on theelimination of electro-optical devices and their associated circuits.Alternative solutions generally use a single energy transfer elementsuch as a transformer or coupled inductor to provide energy to theoutput and also to obtain the information necessary to control theoutput. The lowest cost configuration typically places the controlcircuit and a high voltage switch on the input side of the isolationbarrier.

The controller obtains information about the output indirectly fromobservation of a voltage at either a winding of the energy transferelement or a winding of another switched electromagnetic element. Thewinding that provides the information is on the input side of theisolation barrier. To reduce cost and complexity further, the controllercan also use the same winding of the energy transfer element to obtaininformation about the input to the power supply. A difficulty with theuse of a switched magnetic element to obtain the information necessaryto control the power supply is that the controller receives noinformation during periods where there is no switching. Therefore, thecontroller must force the switch to switch often enough for it torespond adequately to changes in the load.

The input side of the isolation barrier is sometimes referred to as theprimary side, and the output side of the isolation barrier is sometimesreferred to as the secondary side. Windings of the energy transferelement that are not galvanically isolated from the primary side arealso primary side windings, sometimes called primary referencedwindings. A winding on the primary side that is coupled to an inputvoltage and receives energy from the input voltage is sometimes referredto simply as the primary winding. Other primary referenced windings thatdeliver energy to circuits on the primary side may have names thatdescribe their principal function, such as for example a bias winding,or for example a sense winding. Windings that are galvanically isolatedfrom the primary side windings are secondary side windings, sometimescalled output windings.

Power supply controllers that obtain information about an output on thesecondary side from a winding on the primary side, especially when theinformation is in the form of a pulsating signal, are sometimes referredto as having primary side controllers, and the power supplies are saidto operate with primary side control.

Existing controllers for power supplies that reduce the effectiveswitching frequency by either allowing or preventing switching duringgroups of switching periods have difficulty meeting cost and performancerequirements in galvanically isolated applications. A low-cost solutionis needed for primary side controllers to avoid effective switchingfrequencies that fall within the range of undesirable audio frequencieswhile allowing adequate control of the output.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present invention aredescribed with reference to the following figures, wherein likereference numerals refer to like parts throughout the various viewsunless otherwise specified.

FIG. 1 is a functional block diagram that shows an example of a powersupply with a primary side controller in accordance with the teachingsof the present invention.

FIG. 2 is an example flow diagram illustrating generally a sample flowof operations of an example switching power supply providing power to aload in accordance with the teachings of the present invention.

FIG. 3 is schematic diagram showing a portion of an example controllerfor a power supply that illustrates an example circuit for minimum-summulti-cycle modulation in accordance with the teachings of the presentinvention.

FIG. 4 is a timing diagram that shows signals in the example minimum-summulti-cycle modulation circuit example shown in FIG. 3.

FIG. 5 is another example flow diagram illustrating generally a sampleflow of operations of another example switching power supply providingpower to a load in accordance with the teachings of the presentinvention.

FIG. 6 is yet another example flow diagram illustrating generally asample flow of operations of another example switching power supplyproviding power to a load in accordance with the teachings of thepresent invention.

DETAILED DESCRIPTION

Methods and apparatuses for controlling a power supply with minimum-summuti-cycle modulation are disclosed. In the following description,numerous specific details are set forth in order to provide a thoroughunderstanding of the present invention. It will be apparent, however, toone having ordinary skill in the art that the specific detail need notbe employed to practice the present invention. In other instances,well-known materials or methods have not been described in detail inorder to avoid obscuring the present invention.

Reference throughout this specification to “one embodiment”, “anembodiment”, “one example” or “an example” means that a particularfeature, structure or characteristic described in connection with theembodiment or example is included in at least one embodiment of thepresent invention. Thus, appearances of the phrases “in one embodiment”,“in an embodiment”, “one example” or “an example” in various placesthroughout this specification are not necessarily all referring to thesame embodiment or example. Furthermore, the particular features,structures or characteristics may be combined in any suitablecombinations and/or subcombinations in one or more embodiments orexamples. Particular features, structures or characteristics may beincluded in an integrated circuit, an electronic circuit, acombinational logic circuit, or other suitable components that providethe described functionality. In addition, it is appreciated that thefigures provided herewith are for explanation purposes to personsordinarily skilled in the art and that the drawings are not necessarilydrawn to scale.

To illustrate, the schematic diagram of FIG. 1 shows salient features ofone example of a dc-dc power supply 100 with galvanic isolation thatreceives an input voltage V_(IN) 102 to produce an output voltage V_(O)120 and an output current I_(O) 118 to a load (not shown in FIG. 1) inaccordance with the teachings of the present invention. In an example ofan ac-dc power supply, the dc input voltage V_(IN) 102 may be arectified and filtered ac input voltage. Input voltage V_(IN) 102 ispositive with respect to an input return 104. Output voltage V_(O) 120is positive with respect to an output return 122. In other examples, thepower supply may have more than one output.

The dc-dc power supply 100 in the example of FIG. 1 includes an energytransfer element T1 124 and a switch S1 156. The switch S1 156represents the operation of a controlled semiconductor device such asfor example a metal oxide semiconductor field effect transistor (MOSFET)or for example a bipolar junction transistor (BJT). The dc-dc powersupply 100 in the example of FIG. 1 also includes a controller 138 thatreceives a current sense signal 136 and a voltage sense signal 152. Inthe example of FIG. 1, a voltage sense circuit 130 produces a pulsatingvoltage V_(B) 128 that may be positive and negative with respect to theinput return 104.

In the example illustrated in FIG. 1, energy transfer element T1 124 isa coupled inductor, sometimes referred to as a transformer, with threewindings. Winding 110 is a primary winding that has one end coupled tothe input voltage V_(IN) 102 and the opposite end coupled to the switchS1 156. Winding 112 is a secondary winding that has one end coupled tothe output return 122 and the opposite end coupled to an outputrectifier D1 114. Winding 126 is a sense winding, sometimes referred toas a bias winding, with one end coupled to the input return 104. Thepolarities of the windings, indicated by the dots at one end of eachwinding (dotted ends have the same polarity), show that the example ofFIG. 1 is configured to be a flyback power supply.

In the operation of the flyback power supply example of FIG. 1,controller 138 produces a drive signal U_(D) 154 that may open and closeswitch S1 156 within repetitive switching periods of duration T_(S).When switch S1 156 is closed (also referred to as being ON or being inan ON state), the switch S1 156 may conduct current I_(P) 134 in theprimary winding 110 of energy transfer element 124. When switch S1 156is open (also referred to as being OFF or being in an OFF state), theswitch S1 156 cannot conduct current.

When switch S1 156 is ON, the voltage V_(P) 108 across the primarywinding 110 of the energy transfer element 124 is the input voltageV_(IN) 102. While switch S1 is ON in the example of FIG. 1, primarycurrent I_(P) 134 increases until it reaches a value of a variablecurrent limit I_(PK) 132. In the example of FIG. 1, there issubstantially no current in secondary winding 112 and substantially nocurrent in sense winding 126 while switch S1 156 is ON.

Controller 138 senses a pulsating primary current I_(P) 134 that is alsothe current in the switch S1 156 as a current sense signal 136. Any ofthe many known ways to sense current, such as for example receiving thevoltage across a resistor conducting the current, or for examplereceiving a scaled current from a current transformer, or for examplereceiving the voltage across the on-resistance of a metal oxidesemiconductor field-effect transistor (MOSFET) that conducts thecurrent, may be used to sense the primary current I_(P) 134 and toprovide current signal 136 to controller 138.

The waveforms of current and voltage illustrated in the example of FIG.1 show that the power supply 100 is operating in the discontinuousconduction mode (DCM), which is typical for operation at light loads. Adistinguishing characteristic of operation in DCM is that the primarycurrent I_(P) 134 is zero immediately after the switch S1 156 turns ON.At higher loads, the power supply typically operates in the continuousconduction mode (CCM), which is distinguished by a jump in primarycurrent I_(P) 134 from zero to a finite positive value immediately afterthe switch S1 156 turns ON, not shown in FIG. 1.

When primary current I_(P) 134 reaches the value of a variable currentlimit I_(PK) 132, controller 138 opens switch S1 156 and current I_(P)134 falls to zero. A clamp circuit 106 is typically coupled acrossprimary winding 110 to limit the voltage on switch S1 156 when switch S1156 opens.

When controller 138 opens the switch S1 156, energy stored in coupledinductor T1 124 while the switch S1 156 was conducting produces acurrent in secondary winding 112. The pulsating current in secondarywinding 112 is rectified by diode D1 114 and filtered by capacitor C1116 to produce a substantially dc output voltage V_(O) 120.

The switching of switch S1 156 produces a voltage V_(B) 128 on biaswinding 126 that is related by transformer action to the voltages onprimary winding 110 and secondary winding 112. When switch S1 156 is ON,the voltage V_(B) 128 is negative with respect to the output return 104with a magnitude that is substantially the input voltage V_(IN) 102scaled by the turns ratio that is the number of turns on winding 126divided by the number of turns on winding 110. When switch S1 156 turnsOFF and diode D1 114 is conducting, the voltage V_(B) 128 is positivewith respect to the output return 104 with a value that is substantiallythe output voltage V_(O) 120 plus the voltage across diode D1 114 whenthe diode is conducting, the sum scaled by the turns ratio, which is thenumber of turns on winding 126 divided by the number of turns on winding112.

Controller 138 in the example of FIG. 1 includes a signal separator 150to extract the sensed input voltage V_(INSENSE) and the sensed outputvoltage V_(OSENSE) from voltage sense signal V_(SENSE) 152. In oneexample, signal separator 150 may be a rectifier followed by a sampleand hold circuit that provides a substantially dc feedback signal U_(FB)144 that is representative of the output voltage V_(O) 120.

Controller 138 in the example of FIG. 1 also includes an error amplifier146 that produces an error signal U_(ERROR) 148 from the differencebetween the feedback signal U_(FB) 144 and a reference signal U_(REF)142. The reference signal U_(REF) 142 is representative of the desiredvalue of the output V_(O) 120, whereas the feedback signal U_(FB) 144 isrepresentative of the actual value of the output voltage V_(O) 120. Inone example, error amplifier 146 includes an integrator that integratesthe difference between the reference signal U_(REF) 142 and the feedbacksignal U_(FB) 144. In other examples, error amplifier 146 may include adifferentiator as well as an integrator to provide desiredcharacteristics for the stability and the behavior of the power supplyin response changes in input voltage V_(IN) 102 and output current I_(O)118 as is well known in the art.

Controller 138 in the example of FIG. 1 also includes a control circuit140 that receives the error signal U_(ERROR) 148 and produces the drivesignal U_(D) 154 that switches the switch S1 156. Control circuit 140 inthe example of FIG. 1 may include various analog and digital circuitssuch as for example counters 158, logic gates 160, and oscillators 162,to provide the desired relationships among the error signal U_(ERROR)148, the current sense signal 136, and the drive signal U_(D) 154.

The control circuit 140 may filter the current sense signal 136 and theerror signal 148 U_(ERROR) in various ways to provide the desiredbehavior of the power supply under a variety of conditions such as forexample, startup, shutdown, overload, light load, and no-load.

In one example, control circuit 140 adjusts the value of the variablecurrent limit I_(PK) 132 in response to the error signal U_(ERROR) 148so that the output voltage V_(O) 120 is regulated at a desired value.When the switching period T_(S) is fixed, adjustment of the variablecurrent limit I_(PK) 132 changes the duration that the switch S1 156 isON, sometimes referred to as the on-time. The duration that the switchS1 156 is ON is also sometimes referred to as the on-time interval ofthe cycle. This type of control may be described as peak current pulsewidth modulation (PWM) with fixed frequency. It is sometimes referred toas fixed frequency peak current mode control or just current modecontrol.

In other examples, the control circuit 140 may directly adjust the timethat the switch S1 156 is ON within a fixed switching period when theprimary current 134 is less than a fixed current limit. This type ofcontrol sometimes referred to as fixed frequency voltage mode PWM, orfixed frequency duty ratio control.

In yet other examples, the control circuit 140 may fix the on-time ofthe switch when the primary current 134 is less than a fixed currentlimit and it may adjust a variable switching period to regulate theoutput. Alternatively, the control circuit 140 may set a fixed currentlimit to turn the switch OFF, and it may adjust a variable switchingperiod to regulate the output. The control circuit may vary the lengthof time the switch is ON and OFF in many different ways to regulate theoutput of the power supply at moderate to heavy loads.

At light loads the controller 138 may use a circuit to control the powersupply such that switching events are gathered into groups ofconsecutive periods where switching occurs, separated by groups ofconsecutive periods where switching does not occur, and the sum of thenumber of periods in a group where switching occurs plus the number ofperiods in a group where switching does not occur is always greater thanor equal to a minimum value. This type of control may be described asminimum-sum multi-cycle modulation. In one example, the sum of thenumber of enabled periods plus the number of skipped periods is aconstant. Minimum-sum multi-cycle modulation restricts the grouping ofenabled periods and skipped periods to avoid effective switchingfrequencies that fall within the range of undesirable audio frequencieswhile allowing adequate control of the output.

FIG. 2 is an example flow diagram that describes generally a method tocontrol a power supply according to the teachings of the presentinvention. Starting in block 205, sensing of power supply output(s)occurs at block 210. In a power supply with primary side control, theoutputs are sensed from a winding on the input side of the power supply.

Next, in block 215, the controller uses information sensed about thepower supply output(s) to determine the peak current I_(PK) 132 requiredto regulate the output with a fixed switching period T_(S). Next, thevalue of peak current I_(PK) 132 is compared to a minimum peak currentI_(PKMIN) at a decision block 220. In one example, the minimum peakcurrent I_(PKMIN) corresponds to a minimum time that output rectifier D1114 must conduct for reliable sensing of the output voltage V_(O) 120.In one example, the minimum peak current I_(PKMIN) is 25% of the maximumpeak current allowed by the design of the power supply.

In one example, the peak current I_(PK) 132 is determined from themagnitude of an error signal such for example U_(ERROR) 148 in FIG. 1. Asmall error signal typically implies a light load that demands a reducedeffective switching frequency to meet the requirements of highefficiency. Under those conditions, decision block 220 finds thatI_(PK)<I_(PKMIN), and the flow is directed to block 230. Peak currentI_(PK) 132 is fixed at the value I_(PKMIN) and the period of theswitching cycle T_(S) is fixed at the value T_(SG) in block 230.Regulation is then accomplished with minimum-sum multi-cycle modulationin a block 235.

As shown in block 235, minimum-sum multi-cycle modulation accomplishesregulation of the output by enabling N periods of switching in theswitch signal, each having period T_(SG), followed by no switching for Mperiods of T_(SG). In the example, the sum of N and M is restricted tobe greater than or equal to a minimum value K, where the value of K ischosen to meet the performance requirements of the intended application.Minimum-sum multi-cycle modulation places a minimum value on the groupperiod T_(G). In the example, minimum-sum multi-cycle modulation inaccordance with the teachings of the present invention avoids thegeneration of undesirable audio frequencies while allowing the powersupply to meet requirements of cost, efficiency, and output regulation.

In one example, I_(PKMIN) is set at approximately 25% of the peakcurrent at maximum output power of the power supply. In one embodiment,the fixed switching frequency is 30 kHz and the value of K is 6 toestablish a maximum effective switching frequency of 5 kHz. The maximumeffective switching frequency, although in the range of human hearing,may be outside the range of audio frequencies that excite mechanicalresonances in the components of the power supply.

If the decision block 220 finds that I_(PKMIN)≦I_(PK), then the flow isdirected to a block 225 so that regulation is accomplished with peakcurrent PWM at fixed switching frequency instead of minimum-summulti-cycle modulation. In one example, minimum-sum multi-cyclemodulation may be used to regulate the delivery of low output power, andfixed frequency peak current PWM (also known as fixed frequency peakcurrent mode control) may be used to regulate the delivery of higheroutput power in accordance with the teachings of the present invention.

Thus, in one example, dependent upon the relationship between peakswitch current I_(PK) and minimum peak switch current I_(PKMIN), theswitch may be controlled to conduct according to a first or a secondoperating mode. In the first operating mode, a switch is controlled toconduct during a fixed time within the switching period and the peakswitch current within the fixed switching period is adjusted to regulatethe output of a power supply. Alternatively, in a second operating mode,the switch may be controlled to conduct within a fixed switching period,one group of consecutive switching periods separated from a next groupof consecutive switching periods by a time of no switching, the time ofno switching is adjusted to regulate the output of the power supply. Inthe example, the time of no switching may be adjusted so that theeffective switching frequency either falls outside an audible frequencyrange or falls below a frequency within an audible frequency range, theadjustment restricted such that the sum of the number of periods in agroup where switching occurs plus the number of periods in the nextgroup where switching does not occur is greater than or equal to aminimum value.

In one example, period modulation, also known as frequency modulation,could be used instead of peak current mode PWM to regulate delivery ofhigher power in accordance with the teachings of the present invention.In that example, the decision to use period modulation versusminimum-sum multi-cycle modulation would consider the equivalentswitching frequency rather than the peak current that is needed to keepthe output in regulation. For example, when the switching periodincreases in response to the feedback signal and crosses a thresholdthat would indicate a light load, the operation is changed from periodmodulation to minimum-sum multi-cycle modulation.

In another example, fixed frequency voltage mode PWM could be usedinstead of peak current mode PWM to regulate delivery of higher power inaccordance with the teachings of the present invention. In that example,the decision to use PWM versus minimum-sum multi-cycle modulation wouldconsider the on-time of the switch rather than peak current that isneeded to keep the output in regulation. For example, when the on-timedecreases in response to the feedback signal and crosses a thresholdthat would indicate a light load, the operation is changed from fixedfrequency voltage mode PWM to minimum-sum multi-cycle modulation.

FIG. 3 is a schematic diagram 300 that shows one example of a circuitfor minimum-sum multi-cycle modulation in accordance with the teachingsof the present invention. The schematic diagram 300 of FIG. 3 is aportion of a control circuit 140 included in an example controller 138for an example power supply, such as for example power supply 100 ofFIG. 1. As shown, the minimum-sum multi-cycle modulation circuit exampleof FIG. 3 includes inverter 306, AND gates 308 and 334, latches 310 and338, monostable multivibrator 312, oscillator 316 and counter 322. FIG.4 is a timing diagram 400 that shows the relationships among signals inthe schematic diagram of FIG. 3.

In the depicted example, oscillator 316 in FIG. 3 provides a clocksignal 318 that establishes the switching frequency and marks theswitching periods for the power supply. In one example, clock signal 318is also distributed throughout various circuits in the controller notshown in FIG. 3. FIG. 4 shows clock signal 318 marking the start of 16consecutive switching periods 405, each with duration T_(S). In theexample of FIG. 4, the drive signal U_(D) 154 is synchronized with theclock signal 318. The rising edge of the drive signal U_(D) 154 in thefirst switching period in the sequence of switching periods 405 iscoincident with the rising edge of the clock signal 318 at time t₀ 410.

When the power supply operates with minimum-sum multi-cycle modulation,the circuit in FIG. 3 receives a START SKIP signal 302 and a STOP SKIPsignal 304 to produce a SKIP signal 342. In the minimum-sum multi-cyclemodulation circuit of FIG. 3, the START SKIP signal 302 and the STOPSKIP signal 304 may be considered inputs, and the SKIP signal 342 may beconsidered the output. In one example, the SKIP signal 342 inhibits thedrive signal U_(D) 154 so that switching cannot occur when the SKIPsignal 342 is at a high logic level. In one example, a simple logiccircuit such as an AND gate (not shown) receiving the complement of SKIPsignal 342 at one input and receiving a drive command at another inputmay be inhibit the drive signal U_(D) 154 when SKIP signal 342 is high.

In one example, a logic circuit (not shown) generates the START SKIPsignal 302 and the STOP SKIP signal 304 in response to the error signalU_(ERROR) 148. When the error signal U_(ERROR) 148 falls below a skipthreshold, a logic circuit produces a pulse that is the START SKIPsignal 302. When the error signal U_(ERROR) 148 rises above the skipthreshold, a logic circuit produces a pulse that is the STOP SKIP signal304.

In the absence of the minimum-sum multi-cycle modulation circuitexplained below, the START SKIP signal 302 would begin a sequence ofswitching periods where switching is prevented, and the STOP SKIP signal304 would begin a sequence of switching periods where switching isallowed. In the example of FIG. 3, the minimum-sum multi-cyclemodulation circuit monitors the SKIP signal 342 and masks the START SKIPsignal 302 when necessary to restrict the number of skipped periods suchthat the sum of the number of switching periods N in a group whereswitching is allowed plus the number of switching periods M in thefollowing group where switching is prevented is greater than or equal toa minimum number K.

In the timing diagram of FIG. 4, switching events 470, 475, 480, and 485of the drive signal U_(D) 154 are marked by an asterisk to indicate thatthose events would have been skipped if the minimum-sum multi-cyclecircuit had not masked the START SKIP signal 302 from latch 310. At timet₀ 410, START SKIP signal 302, STOP SKIP signal 304, ONE-SHOT signal314, SKIP MASK signal 340, and SKIP signal 342 are at a logic low level.Since SKIP signal 342 is low at time t₀ 410, the pulse from CLOCK signal318 at time t₀ 410 begins an enabled switching period where the drivesignal U_(D) 154 goes high. Drive signal U_(D) 154 stays high untilcurrent sense signal 136 in FIG. 1 reaches the current limit valueI_(PK) 132 also shown in FIG. 1. The next switching period that beginsat time t₁ 415 is also an enabled switching period in which drive signalU_(D) 154 goes high again.

SKIP signal 342 and SKIP MASK signal 340 remain low until the START SKIPsignal 302 goes high at time t₂ 420. When START SKIP signal 302 goeshigh at time t₂ 420, latch 310 sets SKIP signal 342 to a high logiclevel. A high level on SKIP signal 342 disables switching (prevents theswitch S1 156 from turning on). Therefore, drive signal U_(D) 154 stayslow while SKIP signal 342 is high. SKIP signal 342 remains high untilSTOP SKIP signal 304 goes high at time t₃ 425.

When SKIP signal 342 goes to a high logic level at time t₂ 420,monostable multivibrator 312, also called a one-shot, produces an outputsignal 314 that sets SKIP MASK signal 340 that is an output of latch 338to a high logic level. Output signal 314 from one-shot 312 is receivedat a RESET input 320 of counter 322 to set outputs 326, 328, 330, and332 to zero (low logic levels). Outputs 326, 328, 330, and 332 ofcounter 322 represent respectively the least significant to the mostsignificant binary digits of the value of the count of counter 322. SKIPMASK signal 340 is also received at an ENABLE input 324 of counter 322.When SKIP MASK signal 340 goes high, counter 322 begins to count pulsesof the CLOCK signal 318. In other examples, ENABLE input 324 of counter322 may be fixed at a high logic level instead of receiving SKIP MASKsignal 340 so that counter 322 counts continuously. A counter enabled bySKIP MASK signal 340 has reduced switching loss, whereas a counteroperating continuously may provide a continuous clock signal at areduced frequency for use by other circuits not shown in FIG. 3.

SKIP MASK signal 340 stays high until one or more outputs of counter 322reaches a value that causes the output of AND gate 334 to reset latch338. In the example of FIG. 3, the value of the output 336 of counter322 that resets latch 338 is 6, or a binary value of 0110, because thetwo inputs of AND gate 334 receive outputs 328 and 330 from counter 322.Outputs 328 and 330 from counter 322 are both high when the counterreaches a value of 6.

In another example, other outputs from counter 322 may be received by anAND gate with two more inputs to reset latch 338 at a different valuefrom counter 322. In yet another example, a more elaborate logic circuitmay receive outputs from counter 322 and be logically combined witheither control signals or programming signals so that the count thatresets latch 322 may be changed dynamically according to the needs ofthe power supply.

In the example timing diagram of FIG. 4, START SKIP signal 302 goes highat time t₄ 430, but SKIP signal 342 does not go high at time t₄ 430because it is masked by SKIP MASK signal 340. A high logic level on SKIPMASK signal 340 is inverted by inverter 306 to apply a low logic levelat an input of AND gate 308, thereby preventing START SKIP signal 302from setting latch 310. In the absence of the minimum-sum multi-cyclemodulation circuit of FIG. 3, SKIP signal 342 in FIG. 4 would go high attime t₄ 430 and would go low at time t₆ 440 in response to START SKIPsignal 302 and STOP SKIP signal 304 respectively, as indicated by thedashed lines on SKIP signal 342 in FIG. 4 between times t₄ 430 and t₆440.

In the example of FIG. 4, SKIP MASK signal 340 goes high at time t₂ 420and stays high for K counts of CLOCK signal 318, going low at time t₅435. Since FIG. 4 shows the operation of the example circuit of FIG. 3,K=6 and the SKIP MASK signal 340 goes low on the sixth pulse of CLOCKsignal 318 after SKIP MASK signal 340 enables counter 322 at time t₂420.

FIG. 4 shows that the START SKIP signal 302 goes high at time t₄ 430,but SKIP signal 342 does not go high at time t₄ 430 because SKIP MASKsignal 340 is high at time t₄ 430, causing AND gate 308 to prevent STARTSKIP signal 302 from setting latch 310.

The example of FIG. 4 shows that START SKIP signal 302 goes high againat time t₇ 445 when SKIP MASK signal 340 is low. Therefore, START SKIPsignal 302 sets latch 310 to raise SKIP signal 342 to a high logiclevel. The transition of SKIP signal 342 produces a pulse of ONE-SHOTsignal 314 from monostable multivibrator 312 that sets latch 338 andresets counter 322.

The example of FIG. 4 shows that SKIP signal 342 goes low at time t₈ 450in response to STOP SKIP signal 304, but SKIP signal 342 does not gohigh at time t₉ 455 in response to START SKIP signal 302 because SKIPMASK signal 340 is still high at time t₉ 455. SKIP MASK signal 340remains high until time t₁₀ 460, when counter 322 reaches the sixthcount of CLOCK signal 318 after counter 322 was reset and enabled attime t₇ 445. Counter 322 and AND gate 334 may be considered a filtercircuit that resets SKIP MASK signal 340 in response to SKIP signal 342and CLOCK signal 318.

In the example of FIG. 4, SKIP MASK signal 340 allows switching events475, 498, and 485 to occur after START SKIP signal 302 goes high at timet₉ 455. STOP SKIP signal 304 goes high at time t₁₁ 465, but it has noeffect because SKIP signal 342 did not go high when START SKIP signal302 went high at time t₉ 455. In the absence of the minimum-summulti-cycle modulation circuit, SKIP signal 342 would go high at time t₉455 as indicated by the broken lines on SKIP signal 342 between times t₉455 and t₁₁ 465.

As illustrated by the examples of FIG. 3 and FIG. 4, minimum-summulti-cycle modulation puts a lower bound on the number of enabled anddisabled switching periods. Minimum-sum multi-cycle modulation does notimpose an upper bound on either the number of enabled switching periodsor the number of disabled switching periods. Therefore, under conditionsof no load, switching could be disabled indefinitely by an unlimitednumber of skipped periods. To avoid problems with extended times of noswitching, controllers for power supplies that use primary side controltypically have a timer that puts an upper bound on the time betweenswitching events. In one example, a timer (not shown in controller 138)forces switch S1 156 to close at least every 4 milliseconds.

FIG. 5 is another example flow diagram that describes generally anothermethod to control a power supply according to the teachings of thepresent invention. Starting in block 505, sensing of power supplyoutput(s) occurs at block 510.

Next, in block 515, the controller uses information sensed about thepower supply output(s) to determine an equivalent switching frequencyf_(EQ) required to regulate the power supply output with periodmodulation that varies the switching period T_(S). Next, the value ofthe equivalent switching frequency f_(EQ) is compared to a referencevalue f_(REF) at a decision block 520. In one example, the referencefrequency f_(REF) is greater than or equal to the highest audiofrequency of interest. In one embodiment, the reference frequency isapproximately 30 kHz.

In one example, switching frequency f_(EQ) is estimated to be higher orlower than reference frequency f_(EQ) on the basis of a feedback signal.An estimate of f_(EQ) lower than f_(REF) implies a light load thatdemands a switching frequency within the range of audio frequencies.Under these conditions, decision block 520 finds that f_(REF)>f_(EQ) andthe flow is directed to block 530. Regulation is then accomplished withminimum-sum multi-cycle regulation in block 535.

As shown in block 535, minimum-sum multi-cycle modulation accomplishesregulation of the output by enabling N periods of switching in theswitch signal, each having period T_(SG), followed by no switching for Mperiods of T_(SG). In the example, the sum of N and M is restricted tobe greater than or equal to a minimum value K, where the value of K ischosen to meet the performance requirements of the intended application.In the example, minimum-sum multi-cycle modulation in accordance withthe teachings of the present invention avoids the generation ofundesirable audio frequencies while allowing the power supply to meetrequirements of cost, efficiency, and output regulation.

If the decision block 520 finds that f_(REF)≦f_(EQ), then the flow isdirected to a block 525 so that regulation is accomplished with periodmodulation instead of minimum-sum multi-cycle modulation. In oneexample, minimum-sum multi-cycle modulation may be used to regulate thedelivery of low output power, and period modulation (also known asfrequency modulation) may be used to regulate the delivery of higheroutput power in accordance with the teachings of the present invention.

FIG. 6 is yet another example flow diagram that describes generally yetanother method to control a power supply according to the teachings ofthe present invention. Starting in block 605, sensing of power supplyoutput(s) occurs at block 610.

Next, in block 615, the controller uses information sensed about thepower supply output(s) to determine an on-time T_(ON) of a switch withina fixed switching period T_(S) required to regulate the power supplyoutput with pulse width modulation at a fixed switching frequency. Next,the value of the on-time T_(ON) is compared to a reference minimum valueT_(ONMIN) at a decision block 620. In one example, the minimum on-timeis the smallest on-time that can be controlled by the control circuit.In one embodiment, minimum on-time T_(ONMIN) is approximately 600nanoseconds. Under conditions where the control circuit cannot reducethe on-time further, a different parameter must be varied to regulatethe output.

In one example, on-time T_(ON) is estimated to be higher or lower thanthe minimum value T_(ONMIN) on the basis of a feedback signal. Anestimate of T_(ON) lower than T_(ONMIN) implies a light load thatdemands a switching frequency within the range of audio frequencies.Under these conditions, decision block 620 finds that T_(ONMIN)>T_(ON)and the flow is directed to block 630. Regulation is then accomplishedwith minimum-sum multi-cycle regulation in block 635.

As shown in block 635, minimum-sum multi-cycle modulation accomplishesregulation of the output by enabling N periods of switching in theswitch signal, each having period T_(SG), followed by no switching for Mperiods of T_(SG). In the example, the sum of N and M is restricted tobe greater than or equal to a minimum value K, where the value of K ischosen to meet the performance requirements of the intended application.In the example, minimum-sum multi-cycle modulation in accordance withthe teachings of the present invention avoids the generation ofundesirable audio frequencies while allowing the power supply to meetrequirements of cost, efficiency, and output regulation.

If the decision block 620 finds that T_(ONMIN)≦T_(ON), then the flow isdirected to a block 625 so that regulation is accomplished with fixedfrequency pulse width modulation. In one example, minimum-summulti-cycle modulation may be used to regulate the delivery of lowoutput power, and fixed frequency pulse width modulation may be used toregulate the delivery of higher output power in accordance with theteachings of the present invention.

The above description of illustrated examples of the present invention,including what is described in the Abstract, are not intended to beexhaustive or to be limitation to the precise forms disclosed. Whilespecific embodiments of, and examples for, the invention are describedherein for illustrative purposes, various equivalent modifications arepossible without departing from the broader spirit and scope of thepresent invention. Indeed, it is appreciated that the specific examplevoltages, currents, frequencies, power range values, times, etc., areprovided for explanation purposes and that other values may also beemployed in other embodiments and examples in accordance with theteachings of the present invention.

These modifications can be made to examples of the invention in light ofthe above detailed description. The terms used in the following claimsshould not be construed to limit the invention to the specificembodiments disclosed in the specification and the claims. Rather, thescope is to be determined entirely by the following claims, which are tobe construed in accordance with established doctrines of claiminterpretation. The present specification and figures are accordingly tobe regarded as illustrative rather than restrictive.

What is claimed is:
 1. A power supply controller, comprising: a signalseparator circuit coupled to generate a feedback signal in response to asense signal representative of an output of a power supply; an errorsignal generator coupled to generate an error signal in response to thefeedback signal and a reference signal; and a control circuit coupled togenerate a drive signal in response to the error signal and a currentsense signal, wherein the drive signal is coupled to control switchingof a switch of the power supply, wherein the current sense signal isrepresentative of a current through the switch; and a multi-cyclemodulation circuit included in the control circuit and coupled togenerate a first signal in response to a second signal, a third signaland a fourth signal, wherein the first signal is coupled to inhibit thedrive signal, wherein the fourth signal is generated in response to thefirst signal, wherein the second signal is coupled to cause the drivesignal to start skipping on-time intervals of cycles, wherein the thirdsignal is coupled to cause the drive signal to stop skipping the on-timeintervals of cycles, wherein the fourth signal is coupled to disable thesecond signal from causing the drive signal to start skipping theon-time intervals of cycles, and wherein a sum of the on-time intervalsof cycles and the skipped on-time intervals of cycles is greater than orequal to a constant, wherein the multi-cycle modulation circuit includesa filter circuit including a counter coupled to a first logical ANDgate, wherein the counter has a plurality of binary outputs that arecoupled to be received by the first logical AND gate, wherein the firstlogical AND gate is coupled to reset the fourth signal in response tothe plurality of binary outputs received from the counter.
 2. The powersupply controller of claim 1 wherein the multi-cycle modulation circuitfurther comprises a first latch coupled to generate the fourth signal,wherein the first latch is coupled to be set in response to the firstsignal and wherein the first latch is coupled to be reset in response tothe filter circuit.
 3. The power supply controller of claim 2 whereinthe multi-cycle modulation circuit further comprises a one-shot circuitcoupled to set the first latch in response to the first signal.
 4. Thepower supply controller of claim 1 wherein the multi-cycle modulationcircuit further comprises an oscillator coupled to generate a clocksignal coupled to be received by the counter.
 5. The power supplycontroller of claim 1 wherein the counter is further coupled to be resetin response to the first signal.
 6. The power supply controller of claim1 wherein the multi-cycle modulation circuit further comprises a latchcoupled to generate the first signal, wherein the latch is coupled to beset in response to the second signal and the fourth signal and whereinthe latch is coupled to be reset in respond to the third signal.
 7. Thepower supply controller of claim 1 wherein the second signal and thethird signal are generated in response to the error signal.
 8. The powersupply controller of claim 1 wherein the control circuit furthercomprises a current limit circuit coupled to generate a variable currentlimit signal to regulate the output of the power supply, the currentlimit circuit coupled to terminate an on-time interval of each cycle ofthe drive signal in response to current sense signal and a variablecurrent limit signal, wherein the multi-cycle modulation circuit iscoupled to generate the first signal in response to the second signal,the third signal and the fourth signal when the variable current limitsignal is less than a threshold current limit value.
 9. A power supplycontroller, comprising: a signal separator circuit coupled to generate afeedback signal in response to a sense signal representative of anoutput of a power supply; an error signal generator coupled to generatean error signal in response to the feedback signal and a referencesignal; and a control circuit coupled to generate a drive signal inresponse to the error signal to control switching of a switch of thepower supply to regulate the output of the power supply, wherein thecontrol circuit further comprises: a frequency variation circuit coupledto vary a switching frequency of the drive signal in response to theerror signal to regulate the output of the power supply; and amulti-cycle modulation circuit coupled to generate a first signal inresponse to a second signal, a third signal and a fourth signal when theswitching frequency of the drive signal is greater than a thresholdswitching frequency value, wherein the fourth signal is generated inresponse to the first signal, wherein the first signal is coupled toinhibit the drive signal, wherein the second signal is coupled to causethe drive signal to start skipping on-time intervals of cycles, whereinthe third signal is coupled to cause the drive signal to stop skippingthe on-time intervals of cycles, wherein the fourth signal is coupled todisable the second signal from causing the drive signal to startskipping the on-time intervals of cycles, and wherein a sum of theon-time intervals of cycles and the skipped on-time intervals of cyclesis greater than or equal to a constant, wherein the multi-cyclemodulation circuit includes a filter circuit including a counter coupledto a first logical AND gate, wherein the counter has a plurality ofbinary outputs that are coupled to be received by the first logical ANDgate, wherein the first logical AND gate is coupled to reset the fourthsignal in response to the plurality of binary outputs received from thecounter.
 10. The power supply controller of claim 9 wherein themulti-cycle modulation circuit further comprises a first latch coupledto generate the fourth signal, wherein the first latch is coupled to beset in response to the first signal and wherein the first latch iscoupled to be reset in response to the filter circuit.
 11. The powersupply controller of claim 10 wherein the multi-cycle modulation circuitfurther comprises a one-shot circuit coupled to set the first latch inresponse to the first signal.
 12. The power supply controller of claim 9wherein the multi-cycle modulation circuit further comprises anoscillator coupled to generate a clock signal coupled to be received bythe counter.
 13. The power supply controller of claim 9 wherein thecounter is further coupled to be reset in response to the first signal.14. The power supply controller of claim 9 wherein the multi-cyclemodulation circuit further comprises a latch coupled to generate thefirst signal, wherein the latch is coupled to be set in response to thesecond signal and the fourth signal and wherein the latch is coupled tobe reset in respond to the third signal.
 15. The power supply controllerof claim 9 wherein the second signal and the third signal are generatedin response to the error signal.
 16. A power supply controller,comprising: a signal separator circuit coupled to generate a feedbacksignal in response to a sense signal representative of an output of apower supply; an error signal generator coupled to generate an errorsignal in response to the feedback signal and a reference signal; and acontrol circuit coupled to generate a drive signal in response to theerror signal to control switching of a switch of the power supply toregulate the output of the power supply, wherein the control circuitfurther comprises: a pulse width modulation circuit coupled to vary apulse width of an on-time interval of each cycle of the drive signal inresponse to the error signal to regulate the output of the power supply;and a multi-cycle modulation circuit coupled to generate a first signalin response to a second signal, a third signal and a fourth signal whenthe on-time interval of cycles of the drive signal is less than athreshold on-time value, wherein the first signal is coupled to inhibitthe drive signal, wherein the fourth signal is generated in response tothe first signal, wherein the second signal is coupled to cause thedrive signal to start skipping on-time intervals of cycles, wherein thethird signal is coupled to cause the drive signal to stop skipping theon-time intervals of cycles, wherein the fourth signal is coupled todisable the second signal from causing the drive signal to startskipping the on-time intervals of cycles, and wherein a sum of theon-time intervals of cycles and the skipped on-time intervals of cyclesis greater than or equal to a constant, wherein the multi-cyclemodulation circuit includes a filter circuit including a counter coupledto a first logical AND gate, wherein the counter has a plurality ofbinary outputs that are coupled to be received by the first logical ANDgate, wherein the first logical AND gate is coupled to reset the fourthsignal in response to the plurality of binary outputs received from thecounter.
 17. The power supply controller of claim 16 wherein themulti-cycle modulation circuit further comprises a first latch coupledto generate the fourth signal, wherein the first latch is coupled to beset in response to the first signal and wherein the first latch iscoupled to be reset in response to the filter circuit.
 18. The powersupply controller of claim 17 wherein the multi-cycle modulation circuitfurther comprises a one-shot circuit coupled to set the first latch inresponse to the first signal.
 19. The power supply controller of claim16 wherein the multi-cycle modulation circuit further comprises anoscillator coupled to generate a clock signal coupled to be received bythe counter.
 20. The power supply controller of claim 16 wherein thefilter circuit comprises a counter coupled to be clocked in response tothe clock signal, wherein the counter is further coupled to be reset inresponse to the first signal.
 21. The power supply controller of claim16 wherein the multi-cycle modulation circuit further comprises a latchcoupled to generate the first signal, wherein the latch is coupled to beset in response to the second signal and the fourth signal and whereinthe latch is coupled to be reset in response to the third signal. 22.The power supply controller of claim 16 wherein the second signal andthe third signal are generated in response to the error signal.